Cleaning Device for Condensers

ABSTRACT

There is described a novel cleaning device for a condenser of a chiller system comprising: a condenser provided with a cooling grid, said cooling grid comprising one or more fins; a dust extraction system configured to remove dust from the surface of the one or more fins of the grid and/or the condenser.

FIELD OF THE INVENTION

The present invention relates to cleaning mechanism for use in relation to chiller systems.

More particularly, this invention relates to an apparatus and method for the removal of dust from adjacent the condenser of such chiller systems.

Chiller systems shall include, but shall not be limited to refrigeration systems, cold cabinet systems, freezer systems, air conditioning systems, and the like.

BACKGROUND OF THE INVENTION

Chiller systems, such as, refrigeration systems, cold cabinet systems, freezer systems, air conditioning systems, and the like; rely on a chiller to reduce the temperature of a process fluid, for example, water.

Such chiller systems usually comprise a compressor that constricts or compresses a refrigerant vapour, raising its pressure and pushing through condenser coils. When the compressed gas meets a cooler air temperature it becomes a high pressure liquid. The liquid refrigerant absorbs the heat from the chiller unit, cooling down the air adjacent to the evaporator coils. In doing so, the refrigerant evaporates to gas and flows back to the compressor.

The condenser usually needs to be cooled. Air cooled condensers are the most common form of condensers used in chiller systems. Typically, air cooled condensers comprise one or more condenser coils and one or more fans that induce airflow over the coils. Some chiller systems may also be fitted with a heat exchanger to improve performance and make the system more efficient.

In air cooled chiller systems an array of fins are usually provided, for example, in the form of a grid, to protect the condenser and also to protect users from moving parts.

However, fin grid condensers tend to collect dust, debris and smoke fumes over its grid structure. Such dusts blocks part of the gaps of the grid and negatively affect heat exchange, resulting in reduction in the efficiency of condensing of the condenser.

This means, keeping the dust, debris and fumes out of the condenser and keeping the grid structure of the condenser free of dust, debris and fumes are key to best performance of the condenser.

There is also an adverse effect of dirty and dusty condensers on fans and compressors of the air-conditioners and chill display cabinets units which have to work extra hard to compensate for less efficiency of the condensers. This results in higher energy consumption and a reduction life cycle due to heavy use of component parts.

There are many solutions that have been suggested and tried, but with limited or partial success.

US Patent application No. 2011/296641describes a cleaning brush device for a condenser of refrigerator. The brush device brushes the dust and debris from the cooling fin grid, however, the dust and debris is not removed from the system as a whole and will fall down inside condenser housing the chiller system. This results in and accumulation of dust and debris within the chiller system and constant cleaning of the condenser is still required due to condenser fans powerful airflow suction will take some of the dust and debris back into condenser fins. This is a particular issue for condensers located external to buildings, for example, in air conditioning systems or and exposed to outside open air environment in cities and towns.

US Patent application No. 2002/124586 describes the use of a reversible fan to eliminate dust from condensers. However, this provides only a partial solution, since dust and debris will remain inside the condenser housing unit. In addition, with condensers that are wider and/or longer than normal, areas away from the fan will remain subject to dust accumulation.

Even today a large majority of the condensers used in chiller systems depend upon manual cleaning by maintenance personnel. This will often require regular on site visits by maintenance personnel. More frequent visits by them can be expensive and it is not uncommon to notice condensers not being cleaned for a long time until the chiller system breaks down.

Replacing damaged compressors and other components is very expensive, as is the accumulating cost of inefficient energy usage. Research shows that dirt can increase a chiller system's energy consumption by up to 30%. Furthermore, adding to the high energy bills, there is now a related Climate Change Levy charge reflecting the level of energy use. New building regulations for England and Wales, entitled “Conservation of Fuel and Power L2”, require facilities managers to keep records, which will provide the basis for action to improve energy consumption and CO₂ emissions of chiller systems. There is also an environmental cost, which should concern us all: the effect of depleting fossil fuel resources.

As a result, there is a need for comprehensive device that automatically cleans and maintain the condenser of a chiller system and solves this long term challenge. This present invention aims to solve these needs.

SUMMARY OF THE INVENTION

An objective of the invention is to provide a comprehensive cleaning system for cooling fin grids.

Thus, according a first aspect of the invention there is provided a cleaning device for a condenser of a chiller system comprising:

-   -   a condenser provided with a cooling grid, said cooling grid         comprising one or more fins;     -   a dust extraction system configured to remove dust from the         surface of the one or more fins of the grid and/or the         condenser.

For the avoidance of doubt, the dust extraction system shall not consist of a brush only. However, it is within the scope of the present invention for a brush to be incorporated with other dust extraction systems herein described.

A chiller system according to the present invention shall include, but shall not be limited to a refrigeration system, a cold cabinet system, a freezer system, an air conditioning system, and the like. For example, a chiller system shall include remote air cooled condensers, such as the ALTO™, ADAGIO™ and TENOR™ remote condensers, available in the United Kingdom from Carrier Air Conditioning, Worcestershire B61 0GD. Thus, according to one aspect of the invention the chiller system comprises a refrigeration system. According to another aspect of the invention the chiller system comprises a cold cabinet system. According to another aspect of the invention the chiller system comprises a freezer system. According to another aspect of the invention the chiller system comprises an air conditioning system.

For externally mounted condensers, sensors may be included that detect, for example, temperature, wind, rain, etc. The use of such sensors may be advantageous in that, inter alia, they can help the cleaning operation to work safely, for example, if there is rain and heavy wind the cleaning device can be switched off so that it does not perform its cleaning cycle. This can prevent the cleaning device and/or the condenser from being damaged. In one aspect of the invention rain water may be utilised as a natural cleaning agent, for example, a suction system may be used to wash the condenser and/or grid fins and the spent rain water and dust can be removed together.

The cooling grid will generally comprise a plurality of fins. The fins on the cooling grid may comprise a plurality of horizontal fins, e.g. one or more rows of horizontal fins. Alternatively, the fins on the cooling grid may comprise a plurality of vertical fins, e.g. one or more columns of vertical fins. In certain embodiment of the invention the cooling grid may comprise a plurality of diagonally mounted fins. A particular advantage of the present invention is that the dust extraction system of the invention may be configured to remove dust from any of the aforementioned fin arrangements, including any combination thereof.

It will be understood by the person skilled in the art that the term “dust” shall be interpreted broadly and shall include, but not be limited to, lint, matted dust, dirt, and the like. The term “dust” shall include “dust bunnies”. Dust bunnies, are small agglomerations or clumps of dust that form in areas that are not cleaned regularly. They are generally made of hair, lint, dead skin, spider webs, dust, and sometimes light rubbish and debris. The small agglomerations or clumps are held together by static electricity and/or entanglement. They can house dust mites or other parasites and can lower the efficiency of condensers by clogging. The movement of a single large particle can start the formation of a dust bunny.

The dust extraction system, configured to remove dust from the surface of the one or more fins of the grid, may comprise one or more of a suction system, e.g. a vacuum; a blowing system, e.g. an air blowing system or a washing system, including any combination thereof. Generally, the extraction system is adapted to sweep over the one or more cooling fins, e.g. horizontally, vertically or diagonally, in a predetermined period of time and remove the dust collected in the cooling grid. It is within the scope of the invention for the extraction system to remove dust from the condenser as well as the cooling grid. Furthermore, the extraction system, comprise one or more of a suction system, a blowing system, or a washing system, may also include a brushing system. It is also within the scope of the present invention for the dust extraction system to comprise means for ionisation of the dust, for example, the fins or grid could be ionised, thus preventing attraction of dust to the fins and/or condenser.

Thus, in one aspect of the invention the extraction system comprises a suction system. The suction system may be adapted to clean the grid fins and/or the condenser. The suction system will generally comprise a vacuum. The suction system may comprise one or more vacuum nozzles connected to a vacuum system. The one or more vacuum nozzles will generally be adapted to sweep the grid fins and/or the condenser.

In another aspect of the invention the extraction system comprises a blowing system. The blowing system may be adapted to clean the grid fins and/or the condenser. The blowing system will generally comprise an air blowing system and may comprise one or more air blowing nozzles connected to a blowing system. The one or more air blowing nozzles will generally be adapted to sweep the grid fins and/or the condenser.

In another aspect of the invention the extraction system comprises a washing system. The washing system may be adapted to clean the grid fins and/or the condenser. Furthermore, although the washing system could generally use any liquid suitable for washing, the washing system may comprise the use of water alone or water combined with a choice of cleaning agents, e.g. appropriate chemical cleaning agents. The washing system may comprise one or more washing nozzles connected to a water outlet system. The one or more washing nozzles will generally be adapted to sweep the grid fins and/or the condenser. In addition, it will be understood that the washing system may optionally comprise the use of steam or other vapour or gas.

Another aspect of the invention provides to wash the condenser with both water and appropriate chemicals for cleaning. In another aspect of the invention washing system provides a water spray for the condenser, which may be advantageous during hot days, preventing overheating of the condenser and accelerate heat loss.

The dust extraction system, e.g. the one or more vacuum nozzles, air blowing nozzles or washing nozzles, may sweep horizontally, vertically or diagonally over the cooling fin grid in a predetermined period of time to remove the dust collected in the cooling fin grid. The predetermined period of time may be controlled according to, inter alia, the amount of dust collected on the cooling fin grid. The dust extraction system may sweep a first row horizontally in a first direction from a first side of the cooling fin grid to a second side of the cooling fin grid, move down and sweep vertically to a second row at the second side of the first row, and then sweep the second row horizontally from the second side of the cooling fin grid to the first side of the cooling fin grid. The dust extraction system may sweep the rows and columns of the cooling fin grid from a top row to a bottom row for a first sweep cycle. The dust extraction system may retrace the rows and columns of the cooling fin grid back from a bottom row to a top row for a second sweep cycle, and the first and second sweep cycles may be consecutive such that motion line of the dust extraction system is minimised. Alternatively, the dust extraction system may sweep a first row vertically, depending, inter alia, upon the system being cleaned.

The term between the first and second sweep cycles may be equal to the predetermined period of time. The predetermined period of time may be adjusted according to, inter alia, the nature and performance of the condenser.

The condenser cleaning system of the invention may operate to clean only one side of a condenser and/or grid fins or, more desirably, both sides of the condenser and/or grid fins. When both sides of the condenser and/or grid fins are cleaned, they can be cleaned with parallel running of the cleaning system. Cleaning of both sides of the condenser and/or grid fins may be cleaned by a single cleaning system or two independent cleaning systems may be arranged so that a first cleaning system cleans a first side of the condenser and/or grid fins; and a second cleaning system cleans a second side of the condenser and/or grid fins. When first and second cleaning systems are used in this manner, the cleaning systems may be the same or different.

The dust extraction system may comprise a performance detector, i.e. a detector that measures whether the condenser is operating at optimum efficiency. The predetermined period of time may be adjusted according to an output of the performance detector. The performance detector may comprise a first pressure sensor disposed at an input side of the condenser and a second pressure sensor disposed at out output side of the condenser. Alternatively, the performance detector may comprise one or more cameras that allow an operator to remotely inspect the grid fins and/or the condenser. The dust extraction system may be operated when the ratio of a reading of the second pressure sensor to a reading of the first pressure sensor is above a predetermined value. The performance detector may further comprise a controller for processing outputs from the first and second pressure sensors and controlling operation of the cleaning device, e.g. the dust extraction system. The cleaning device of the invention may be controlled by its own controller device or it may be controlled by a master control system, which may be designed to control an entire suite of cleaning devices, for example, air conditioning controllers, building controllers or chiller cabinet controllers, may operate a suite of chiller devices and cleaning devices. A centralised cleaning system may also comprise a centralised dust collection means.

In a further embodiment, the performance detector may comprise a pressure sensor combined with one or more cameras as herein described. A camera may be used to provide mages of the condenser which may be viewed for various aspects of the system input for control requirements.

The performance detector may also comprise a humidity and/or moisture sensor for the detection of the moisture level on the condenser/fins and also the humidity of the surroundings. The performance detector may also comprise a variety of temperature sensors to detect the heat dissipated.

The cleaning device of the present invention may be adapted to operate in two-dimensions, e.g. horizontally or vertically. Alternatively, the cleaning device of the present invention may be adapted to operate in three-dimensions. Three dimensional operation may be facilitated by the use of a three-dimensional rig. A suitable three-dimensional rig is illustrated in FIGS. 1 and 2 herein.

Thus, according to a further aspect of the invention there is provided a cleaning device as herein described mounted on a three dimensional rig, said rig comprising:

-   -   a cleaning device mount, slidably located on a cross-bar;     -   the cross-bar being slidably mounted on first and second upright         columns; and     -   wherein the first upright column is located on and slidably         mounted in a first base plate; and the second upright column is         located on and slidably mounted in a second base plate.

Alternatively, the invention provides a cleaning device as herein described mounted on a three dimensional rig, said rig comprising:

-   -   a cleaning device mount located at one end of an upright column;     -   said upright column being slidably located on a cross-bar; and     -   said cross-bar being slidably mounted in a pair of base plates.

The invention also provides the use of a three dimensional rig as herein described in conjunction with a cleaning device or method for extracting dust form a condenser and/or grid fins.

The use of the three dimensional rig as herein described is novel per se. The use of the three dimensional rig may be in conjunction with any of the cleaning device embodiments described herein. The three dimensional rig may also be advantageously used in conjunction with other know cleanings systems, for example such as the brush system described in US Patent application No. 2011/296641 and the reversible fan system described in US Patent application No. 2002/124586.

According to a further aspect of the invention there is provided a chiller unit fitted with a dust extraction system as herein described. In particular there is provided a chiller unit fitted with a cleaning device for a condenser of the chiller unit, wherein the condenser of the chiller unit is provided with a cooling grid, said cooling grid comprising one or more fins; and

-   -   the cleaning device comprising a dust extraction system         configured to remove dust from the surface of the one or more         fins of the grid.

The chiller unit according to this aspect of the invention shall include, but shall not be limited to a refrigeration unit, a cold cabinet unit, a freezer unit, an air conditioning unit, and the like.

In a further aspect of the invention there is provided a kit for retrofitting a cleaning device, e.g. a dust extraction system, to a chiller unit, the kit comprising a dust extraction system; control means for operating the dust extraction system for a first predetermined period of time, the time periods being sufficient to effectively extract dust from the grid fins and/or the condenser; the control means including a timer and optionally comprising a performance detector. The chiller unit according to this aspect of the invention shall include, but shall not be limited to a refrigeration unit, a cold cabinet unit, a freezer unit, an air conditioning unit, and the like.

According to a yet further aspect of the invention there is provided a method of cleaning a condenser of a chiller unit wherein said method comprises extracting dust from the condenser of the chiller unit by fitting or retrofitting with a dust extraction system as herein described to the chiller unit. In particular there is provided a method of cleaning a condenser of a chiller unit wherein said method comprises fitting or retrofitting a cleaning device to the chiller unit for a condenser of the chiller unit, wherein the condenser of the chiller unit is provided with a cooling grid, said cooling grid comprising one or more fins; and

-   -   the cleaning device comprising a dust extraction system         configured to remove dust from the surface of the one or more         fins of the grid.

In the method of this aspect of the invention the chiller unit shall include, but shall not be limited to a refrigeration unit, a cold cabinet unit, a freezer unit, an air conditioning unit, and the like.

An objective of the invention is to provide a clean comprehensive automatic dust extraction, air blowing or washing system which can help the efficiency of the condenser life cycle. It is another

The advantages of the present invention include:

-   -   The cleaning devices are able to extract the dust away from the         condenser and/or grid fins.     -   The need for regular maintenance is minimised.     -   Cleaning facilitates improved air flow through or around the         condenser.

It will further be understood by the person skilled in the art that the cleaning device and method of the invention may suitably be used to clean any such condensers or evaporators wherever similar condensers or evaporators are housed. In addition to the aforementioned refrigeration unit, a cold cabinet unit, a freezer unit, an air conditioning unit, examples include, but shall not be limited to, air purification systems, dehumidifier systems, the inside cars, trucks, aircraft, inside of office buildings, retail buildings, houses and factories.

Although the present invention is briefly summarised, the fuller understanding of the invention can be obtained by the following drawings, detailed description and appended claim.

The invention will now be described, by way of example only and with reference to the accompanying figures, in which:

FIG. 1 is a schematic representation of a three-dimensional rig for use in conjunction with cleaning device for a condenser of a chiller system; and

FIG. 2 is a perspective view of a three-dimensional rig for use in conjunction with cleaning device for a condenser of a chiller system.

Referring to FIG. 1, a three-dimensional rig (1) comprises cleaning device mount (2) which is slidably located on a cross-bar (3). The cross-bar (3) is itself slidably mounted in a pair of upright columns (4) and (5). Upright column (4) is located on and slidably mounted in a first base plate (6). Upright column (5) is located on and slidably mounted in a second base plate (7).

In use, a cleaning device, e.g. a dust extraction device (not shown) is located on mount (2). The mount (2) and the cleaning device are slidable on a cross-bar (3) in a horizontal plane (the z-axis in the illustration of FIG. 1). Cross-bar (3) (supporting the mount (2) and the cleaning device) is slidable on the pair of upright columns (4) and (5) in a vertical plane (the y-axis in the illustration of FIG. 1). The pair of upright columns (4) and (5) (supporting cross-bar (3)) is slidable on the base plates (6) and (7) and the upright columns are slidable on the base plates (6) and (7) in a horizontal plane (the x-axis in the illustration of FIG. 1).

Referring to FIG. 2, a three-dimensional rig (8) comprises cleaning device mount (9) which is located at one end of an upright column (10). Upright column (10) is slidably located on a cross-bar (11). The cross-bar (11) is itself slidably mounted in a pair of base plates (12) and (13). A first end (14) of cross-bar (11) is slidably mounted in a first base plate (12). A second end (15) of cross-bar (11) is slidably mounted in a second base plate (13).

In use, a cleaning device, e.g. a dust extraction device (not shown) is located on mount (9) at one end of an upright column (10). Upright column (10) (supporting the mount (9) and the cleaning device) is slidable on a cross-bar (11) in a vertical plane (the y-axis in the illustration of FIG. 2) and in the horizontal plane the z-axis in the illustration of FIG. 2). Each end (14) and (15) of cross-bar (11) are slidable on the base plates (12) and (13) in a horizontal plane (the x-axis in the illustration of FIG. 2). 

I claim: 1-39. (canceled)
 40. A cleaning device for a condenser of a chiller system comprising: a first base plate and a second base plate; an upright column extending from each base plate, each upright column being slidable on said corresponding base plate in an operative horizontal plane; a cross-bar slidably mounted across said upright columns, said sliding operation being configured to be in an operative vertical plane; a cleaning device mount slidably located on said cross-bar, said sliding operation being configured to be in an operative horizontal plane; and a dust extraction system located on said cleaning device mount.
 41. A cleaning device according to claim 1 wherein, the chiller system comprises a system selected from a group of systems consisting of a refrigeration system, a cold cabinet system, a freezer system, an air conditioning system, and a remote chiller system.
 42. A cleaning device according to claim 1 wherein, the chiller system comprises a plurality of fins.
 43. A cleaning device according to claim 1 wherein, the dust extraction system comprises a suction system, characterized in that, said suction system comprising one or more vacuum nozzles connected to a vacuum system.
 44. A cleaning device according to claim 1 wherein, the dust extraction system comprises a suction system, characterized in that, said suction system comprising one or more vacuum nozzles connected to a vacuum system, further characterized in that, said nozzles being adapted to sweep grid fins and condenser.
 45. A cleaning device according to claim 1 wherein, the dust extraction system comprises a blowing system, characterized in that, said blowing system comprising one or air blowing nozzles connected to an air blowing system.
 46. A cleaning device according to claim 1 wherein, the dust extraction system comprises a blowing system, characterized in that, said blowing system comprising one or air blowing nozzles connected to an air blowing system, further characterized in that, said nozzles being adapted to sweep the grid fins and/or the condenser.
 47. A cleaning device according to claim 1 wherein, said dust extraction system comprises a washing system, characterized in that, said washing system comprising one or more washing nozzles connected to a water outlet system.
 48. A cleaning device according to claim 1 wherein, said dust extraction system comprises a washing system, characterized in that, said washing system comprising one or more washing nozzles connected to a water outlet system, further characterized in that, said nozzles being adapted to sweep the grid fins and the condenser.
 49. A cleaning device according to claim 1 wherein, said dust extraction system comprises a washing system, characterized in that, said washing system comprising a water spray.
 50. A cleaning device according to claim 1 wherein, said dust extraction system comprising a brushing system.
 51. A cleaning device according to claim 1 wherein, said system includes a performance detector, characterized in that, said performance detector comprises a first pressure sensor disposed at an input side of the condenser and a second pressure sensor disposed at out output side of the condenser.
 52. A cleaning device according to claim 1 wherein, said system includes a performance detector, characterized in that, said performance detector comprises one or more cameras that allow an operator to remotely inspect the grid fins and/or the condenser.
 53. A cleaning device according to claim 1 wherein, said system includes a performance detector, characterized in that, said performance detector comprises a controller for processing outputs from the first and second pressure sensors and controlling operation of the cleaning device.
 54. A cleaning device according to claim 1 wherein, said system includes a performance detector, characterized in that, said performance detector comprises a pressure sensor combined with one or more cameras.
 55. A cleaning device according to claim 1 mounted on a three dimensional rig, said rig comprising: a cleaning device mount, slidably located on a cross-bar, said cross-bar being slidably mounted on said first and second upright columns, said first upright column being located on and slidably mounted on a first base plate and said second upright column being located on and slidably mounted on a second base plate.
 56. A cleaning device according to claim 1 mounted on a three dimensional rig, said rig comprising: a cleaning device mount, slidably located on a cross-bar, said cross-bar being slidably mounted on said first and second upright columns, said first upright column being located on and slidably mounted on a first base plate and said second upright column being located on and slidably mounted on a second base plate, characterized in that, said dust extraction device being located on said mount at one end of said upright column. 